Nasal Dilator and Method of Manufacture

Abstract

A nasal dilator comprises a laminate of vertically stacked layers forming a unitary, or single body, truss where each layer includes at least one member. The truss features horizontal regions adapted to engage outer wall tissues of first and second nasal passages and to traverse the bridge of a nose therebetween. When in use the dilator acts to stabilize and/or expand the nasal outer wall tissues and prevent said tissues from drawing inward during breathing. Manufacturing methods produce dilator layers and/or finished nasal dilator devices efficiently at the same or lower cost as traditional methods by fabricating dilator elements in whole or part along common lines or edges. Said common lines define peripheral dimensions and form spaced apart relationships between dilator layers, members and finished dilator devices without sacrificing usable material to do so. Manufacturing steps include cutting through a fabrication laminate along lines defining at least portions of one or more layers, members, and the truss's peripheral edges. Manufacturing methods further maximize material usage by incorporating waste material into a subsequent fabrication process. Dilator embodiments further include means for providing disparate dilating force to opposing nasal passages, and means for incorporating promotional printing into the dilator fabrication process.

Description

RELATED APPLICATIONS[0001]This application claims the benefit of U.S. Provisional Application No. 60 / 888,543 filed Feb. 6, 2007 and 61 / 035,972 filed Mar. 12, 2008.FIELD OF THE INVENTION[0002]The present invention relates to apparatus and methods of dilating external tissue. As disclosed and taught in the preferred embodiments, the tissue dilator devices and methods of fabrication of tissue dilators are particularly suitable for use as external nasal dilators for supporting, stabilizing, and dilating nasal tissues adjacent and overlying nasal airway passages, including the nasal valve and / or the vestibule areas thereof.BACKGROUND OF THE INVENTION[0003]A portion of the human population has some malformation of the nasal passages which interferes with breathing, including deviated septa and swelling due to allergic reactions. A portion of the interior nasal passage wall may draw in during inhalation to substantially block the flow of air. Blockage of the nasal passages as a result of m...

AI Technical Summary

Benefits of technology

[0025]Embodiments of the present invention include, without limitation, new and non-obvious means to efficiently manufacture with minimal waste nasal dilator devices and the constituent layers, members and components thereof. Preferred embodiments also include methods for simultaneously fabricating identical, non-identical, symmetric or asymmetric dilator members, components thereof, and finished nasal dilator devices with equal efficiency and with at the same or lower cost as traditional methods. Embodiments further include: means to assist centering on the nose of a wearer comprising a separation, projection or other index marker located at the intermediate region of the dilator; a resilient member or component thereof having a gradiently reduced width; dilator layers, members or components made from materials which are transparent or translucent; and means for incorporating promotional printing and/or contrasting colors (such as team sports colors) into the dilator fabrication process.

[0026]It is the principal objective of this invention to provide nasal dilator devices which overcome the aforementioned limitations and disadvantages of prior dilator devices. A more specific objective of the present invention is to provide nasal dilators and methods of manufacture that minimize material waste and reduce traditional manufacturing cost by configuring device l

Problems solved by technology

A portion of the human population has some malformation of the nasal passages which interferes with breathing, including deviated septa and swelling due to allergic reactions.

Blockage of the nasal passages as a result of malformation, symptoms of the common cold or seasonal allergies are particularly uncomfortable at night, and can lead to sleep disturbances, irregularities and general discomfort.

Said material, such as a spunlaced polyester nonwoven fabric, typically has properties which permit limited, primarily plastic and somewhat elastic deformation within the thickness thereof.

These limitations include limited skin surface area adjacent the nasal passages, adhesive engagement vs. delaminating spring biasing forces, device comfort and durational longevity, and economical fabrication and assembly of dilator components.

Firstly, tissues associated wi

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